Perm National Research Polytechnic University (PNRPU), Perm, Russia:

Yu. D. Shchitsyn, Professor, Head of the Department of Welding, Metrology and Materials Engineering, Doctor of Technical Sciences, e-mail: schicin@pstu.ru
E. A. Krivonosova, Professor at the Department of Welding, Metrology and Materials Engineering, Doctor of Technical Sciences, e-mail: katerinakkkkk@mail.ru
T. V. Olshanskaya, Associate Professor at the Department of Welding, Metrology and Materials Engineering, Doctor of Technical Sciences, e-mail: tvo66@mail.ru
R. G. Nikulin, Postgraduate Student at the Department of Welding, Metrology and Materials Engineering, e-mail: nikromonger.ro@gmail.com

Development of new processes for making magnesium alloy parts with better operational and economic performance is a relevant problem today. This paper describes the results of a study that looked at the use of reverse polarity plasma surfacing to make parts using high-strength light alloy MA5 (magnesium-aluminium-zinc system). Reverse polarity plasma surfacing ensures a clean surface of each previous layer (due to a cathode sputtering effect), good wetting and metal spreading with minimum surface heating. This helps obtain laminar materials with a good structure free of internal defects. The conducted study showed that, with the help of this technique of layer-by-layer synthesis by plasma surfacing, wrought magnesium alloys can be used to make true-to-shape parts. It was found that plasma surfacing ensures a relative structural and phase stability of the material of the previous layers during heat cycles that are a part of the forming process. Slightly bigger sizes of the strengthening phases and proeutectoid constituents were observed. It was found that built-up layers have a higher structural dispersity than ascast or heat treated metal structures produced by conventional technology, the grain size does not exceed 5–15 μm; the hardness of the built-up MA5 material significantly exceeds that of castings (by 2–3 times) or of heat treated magnesium alloy (by 1.5 times).
This research was funded by the Russian Science Foundation, RSF Application No. 21-19-00715 dated 10/11/2020: Control over Micro structure, Strength, Residual Stresses and Geometric Distortions in Hybrid Additive Manufacturing.

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